How a Japanese Automaker Cut Maintenance Costs and Improved Cleanliness with a Custom Abanaki Solution
Oil Skimming That Improved Wash Cleanliness, Extended Fluid Life, and Reduced Maintenance
Automotive manufacturing facilities operate continuous, high-volume production lines where water-based wash systems are used to clean and treat vehicles before shipment. In these environments, contamination from waxes, oils, and process fluids can quickly build up in wash water systems, leading to inefficiencies, equipment issues, and increased maintenance requirements.
At a large Japanese automaker with European operations, a custom oil skimming solution from Abanaki Corporation was implemented to address wax and oil accumulation in production wash water systems at the end of a high-throughput assembly process.
The result was improved wash water performance, reduced manual cleaning, and extended system usability in a demanding 24/7 production environment.
Download Abanaki Model 8 Brochure.
The Challenge: Wax and Oil Contamination in High-Volume Vehicle Wash Systems
At this facility, freshly produced vehicles were sprayed with a protective wax mist as part of the final production stage.
This process created a downstream issue:
- Excess wax overspray accumulated in wash bays and holding sumps
- Sticky residues adhered to existing skimming and drag-out equipment
- Wax hardened quickly, reducing separation efficiency
- Manual cleaning of collection systems was required multiple times per day
- Existing chain-based skimming equipment failed to maintain consistent performance
The existing system not only required frequent labor intervention but also failed to reliably remove wax buildup, resulting in inefficiencies across the wash water system.
The facility needed a more effective method to continuously separate wax and oil while minimizing manual intervention.
The Solution: Installing a Custom Abanaki Belt Oil Skimming System and Operational Benefits
To resolve the issue, the automaker implemented a custom-engineered belt skimming system from Abanaki Corporation, modified specifically for wax-heavy conditions in wash water recovery systems.
The system was designed with enhanced features to handle difficult, sticky contaminants and improve separation efficiency in high-temperature and high-residue environments.
Key enhancements included heating elements and modified wiping components that helped soften wax buildup and improve removal from the belt surface.
Once installed, the system continuously captured floating wax and oil from wash water sumps before buildup could occur.
This implementation delivered several operational benefits:
- Continuous removal of wax and oil contamination reduced accumulation in wash water holding systems – reduction of nearly 90%
- Reduced manual cleaning frequency significantly lowered labor requirements for maintenance teams – savings of several hours a week
- Improved wash water system performance helped extend usable water life and maintain consistent cleaning quality
- Enhanced separation efficiency in challenging conditions addressed sticky, fast-hardening wax that previous systems could not handle
- Reduced equipment fouling and blockage issues improved reliability of downstream wash and spray systems
- Long-term operational stability in 24-hour production lines supported uninterrupted manufacturing flow
The custom design allowed the system to operate effectively in a demanding environment where standard skimming solutions had previously failed.
Why Automotive Manufacturers Use Belt Oil Skimmers
Automotive production facilities use belt oil skimming systems to:
- Maintain clean wash water systems
- Prevent buildup of oils, waxes, and process residues
- Reduce manual maintenance requirements
- Improve consistency in cleaning and surface preparation
- Support continuous, high-volume production operations
Looking for a Reliable Wash Water Oil Removal Solution?
Oil and wax contamination in automotive wash systems can reduce efficiency and increase maintenance workload if not properly managed.
Custom-engineered skimming solutions from Abanaki Corporation provide continuous separation, improved system performance, and reduced operational burden in demanding manufacturing environments.
Frequently Asked Questions
Why does wax create problems in automotive wash systems?
Wax can harden quickly and adhere to equipment, reducing separation efficiency and increasing manual cleaning needs.
How do oil skimmers help in automotive manufacturing?
They continuously remove floating contaminants from wash water, preventing buildup and improving system performance.
Are custom skimming systems necessary in some applications?
Yes. In cases with unusual contaminants like hardened wax, standard systems may require modifications for effective operation.
Do oil skimmers reduce maintenance costs?
Yes. By reducing buildup and cleaning frequency, they lower labor and system maintenance demands.
